Flexible interlocking wall system

ABSTRACT

A masonry wall system is disclosed incorporating a plurality of courses of masonry blocks, each block has vertical and horizontal interlocking structures with mating surfaces ( 11,15,16,17 ). The main block, has a stabilizing slot. Metal reinforcement tendons are inserted into these stabilizing holes ( 14 ) at predetermined intervals and connected to the wall at the top and bottom. Corner blocks ( 26 ) are employed to connect the walls at right angles and are used in alternating configurations to staggered the vertical joints from course to course. This is also done with the main blocks. The predetermined tolerances between the masonry components and the reenforcing tendons permit the wall to have a fluid property. Forces such as settling, hydrostatic pressure and seismic disturbances are then automatically absorbed and systematically distributed across the entire wall. When all of the masonry components reach the end of their tolerance, the wall locks up as a solid interconnected mass. The force is then passed on to the stabilizing tendons which now act to stabilize the wall against further movement. The movement of the wall can be adjusted after assembly of this wall by applying increased tension to the tendons.

This is a continuation-in-part of U.S. patent application Ser. No.09/877,914, filed Jun. 8, 2001, now allowed, which is in turn acontinuation-in-part of U.S. patent application Ser. No. 09/290,635,filed Apr. 12, 1999, now U.S. Pat. No. 6,244,009, which is in turn acontinuation-in-part of U.S. patent application Ser. No. 08/925,311,filed Sep. 8, 1997, now U.S. Pat. No. 5,899,040.

FIELD OF INVENTION

This present invention relates to an improvement in free-standingmortarless building structures and, in particularly, to a virtuallymortarless interconnecting block system with unique dynamic properties.

BACKGROUND OF THE INVENTION

Typically speaking, free-standing masonry walls are constructed ofconcrete blocks (or similar material) in running courses. Each course isplaced in such a manner so that the vertical joints are staggered fromthe previous course. Mortar is used as a binding agent between thecourses and between the ends of each of the blocks. Conventionalconcrete blocks typically have one or more voids extending through themin the vertical direction to create vertical columns through the walls.Reinforcing bars are placed in these columns for enclosure within acontinuous mortar masses within the columns, in accordance with buildingcode standards. Such columns typically are placed approximately fourfeet apart along the length of the wall.

Although this type of free-standing masonry wall has been usedsuccessfully in residential, commercial and industrial construction, itpossesses a considerable number of drawbacks. These include: thenecessity of skilled labor for assembly (not handyman friendly), therequirement of mortar as a binding agent between each of the components,the considerable time demanded for construction, the inability todisassemble components and reuse if desired, the incapacity to absorbexternal pressure changes (such as settling, hydrostatic pressure andseismic disturbances) without significant deterioration to thestructural integrity.

Several types of blocks and wall systems have been proposed to overcomesome of these deficiencies. Beginning in 1901, U.S. Pat. No. 676,803 toShaw, disclosed an interlocking block system that employed a combinationof tongues and groves along with dovetails to secure each block to theadjacent blocks. This was followed by similar designs in U.S. Pat. No.690,811 to Waller, U.S. Pat. No. 748,603 to Henry; U.S. Pat. No. 868,838to Brewington; U.S. Pat. No. 1,562,728 to Albrecht; U.S. Pat. No.2,902,853 Loftstrom; and, French Patent No. 1,293,147. Although the useof interlocking male and female dovetails provide a positive lock andrepresent a significant improvement over similar tongue and groveconstruction, all of the dovetails used in this conventional art embodya critical disadvantage in terms of assembly. When these are employed(as in the case of: U.S. Pat. No. 676,803; French Patent No. 1,293,147;U.S. Pat. No. 748,603; U.S. Pat. No. 1,562,728; and, U.S. Pat. No.2,902,853) on the upper and lower surfaces of the block, the femaledovetail of each new block must be slid over a number of male dovetailson the lower course into the appropriate position. Given the dimensionalinaccuracies of common block material along with the tolerancesnecessary to slide the new block into place, binding is a frequentoccurrence. Despite a long-felt but unresolved need for handymanfriendly construction material, this frequent assembly problem, alongwith the various proprietary components, kept assembly to skilledprofessionals.

While much of the conventional art, to a certain degree, overcomes someof the difficulties associated with the requirement of mortar, and theinability to disassemble, none provide for the capacity to automaticallyabsorb external pressure changes without significant deterioration instructural integrity. Attempts to address this particular problem havecome in the form of steel reinforcement of some kind. In 1907, U.S. Pat.No. 859,663 to Jackson employed steel post, tension-threadedreinforcement rods in combination with steel frames to produce a verystrong wall. The use of steel post, tension-threaded reinforcement rodscan also be seen in: U.S. Pat. No. 3,378,96 to Larger; U.S. Pat. No.859,663 to Jackson; U.S. Pat. No. 4,726,567 to Greenburg; U.S. Pat. No.5,138,808 to Bengtson et al.; and, U.S. Pat. No. 5,355,647 to Johnson etal.

Unfortunately, this move to steel reinforcement as a means to counterexternal pressure meant the loss of many of the gains achieved by muchof the conventional art. In short, the characteristics of: mortarlessconstruction and the ability to disassemble components and reuse themwere sacrificed for a stronger wall.

Although the addition of steel to bind the wall in a solid masscontributed to it structural integrity by better resisting certainexternal forces, this is only true in the case of a force applied in onedirection against the wall. As in the case of hydrostatic pressure, theforce moves only in one direction; from the outside to the inside,slowly and steadily. Seismic disturbances, such as those associate withearthquakes, tend to move the earth in a rapid back and forth motion. Awall bound as a sold mass is unable to accommodate the dynamic back andforth movement. Instead, its rigid composition directly transfers theforce to the rest of the building (acting as sort of a lever) weakeningthe integrity of the entire structure until it finally fails.

Thus, it is desirable to provide a masonry wall system that incorporatesthe advantages of: unskilled labor for assembly; mortarlessconstruction; the ability to disassemble and reuse; and, the necessarycapacity to automatically absorb external pressure changes (particularlyseismic disturbances) without significant deterioration of structuralintegrity. Such a wall system would create a new synergy that wouldsatisfy a long-felt but unresolved need. It would also represent apositive contribution to the masonry industry.

SUMMARY OF THE INVENTION

Accordingly it is an object of the present invention to provide animproved masonry walls system that does not require skilled labor toassemble.

It is another object of the present invention to provide a masonry wallsystem that does not require mortar for it's construction.

It is a further object of the present invention to provide an improvedmasonry wall system that is capable of rapid, on-site assembly.

It is still another object of the present invention to provide animprove masonry wall system that can be disassembled and then reused.

It is still an additional object of the present invention to provide animproved masonry wall system that overcomes the conventional problems ofmasonry assembly in which dovetail structures are used.

It is yet another object of the present invention to provide an improvedmasonry wall system that is capable of absorbing external pressurechanges (such as settling, hydrostatic pressure and seismicdisturbances) without significant deterioration in the structuralintegrity of the wall system.

It is yet a further object of the present invention to provide animproved masonry wall system that is capable of distributing stress onany portion of the wall throughout a large surrounding segment of thewall.

It is again another object of the present invention to provide animproved masonry wall system having a wide variety of interlockingschemes to facilitate flexibility in wall design and construction.

It is still a further object of the present invention to provide animproved masonry wall system that has superior earthquake-resistantproperties to conventional masonry wall systems.

It is yet a further object of the present invention to provide a modelsystem for an improved, mortarless wall system.

It is again another object of the present invention to provide amortarless masonry wall system in which no vertical seams betweenadjacent blocks are lined from row to row, thereby strengthening thewall system.

It is still a further object of the present invention to provide amortarless masonry wall system in which individual blocks interlock witheach other, both vertically and horizontally, using self-containedstructures.

It is an additional object of the present invention to provide amortarless masonry wall system constituted by blocks which are easilyhandled, and quickly and efficiently assembled.

It is yet another object of the present invention to provide amortarless masonry wall system which is flexible in order to compensatefor external stresses on the wall such as seismic activity.

It is again another object of the present invention to provide amortarless masonry wall system having adjustable degrees of flexibilityonce the wall has been assembled, without requiring changes in the sizeand structure of the individual blocks.

It is an additional object of the present invention to provide amortarless masonry wall system admitting to easy insertion of insulatingcords.

It is again a further object of the present invention to provide amortarless masonry wall system which eliminates or greatly reduces pointloading between blocks of the wall.

It is yet another object of the present invention to provide amortarless masonry wall system admitting to varying degrees ofadjustable flexibility, even after the wall has been entirely assembled.

It is again a further object of the present invention to provide amortarless masonry wall system which is capable of extending itsflexibility through the use of additional structures added after thewall is assembled.

It is an additional object of the present invention to provide amortarless masonry wall system which relies upon only two types ofdifferent blocks, thereby simplifying production of the wall componentand ease of assembly.

It is again a further object of the present invention to provide amortarless masonry wall system having the capability of both flexing andreturning to its original position after the removal of externalstresses.

It is yet another object of the present invention to provide amortarless masonry wall system which is flexible and avoids thenecessity of forming rebar holes through the block constituting thewall.

It is still a further object of the present invention to provide amortarless masonry wall system which easily drains water from theinterior of the wall into drainage systems at the foot of the wall.

It is yet a further object of the present invention to provide amortarless masonry wall system which includes internal spaces forconduit within the blocks constituting the wall without the necessity ofcutting holes through the transverse walls of the block.

It is yet a further object of the present invention to provide amortarless masonry wall system which is flexible but provides forhorizontal structures such as lintels.

It is again another object of the present invention to provide amortarless masonry wall system which admits to horizontal reinforcementthrough the adjustment of horizontal pressure on the blocks of the wall.

It is still another object of the present invention to provide amortarless masonry wall system, and a technique for installing the wallsystem whereby the blocks of the wall are properly aligned to the footersupporting the wall.

It is still an additional object of the present invention to provide amortarless masonry wall system in which the wall system is easilysectionalized and braced on a vertical basis for separating differentstories for buildings employing said wall system.

It is again a further object of the present invention to provide amortarless masonry wall system wherein reinforcement is easily added tothe walls by virtue of metal reenforcing structures.

These and other objects and goals of the present invention are achievedby a flexible interlocking wall system including a plurality of blocksarranged for interlocking without mortar, where the wall system has atleast two major surfaces, each major surface forming a wall face. Thewall system includes a plurality of main blocks where each main blockhas at least one stabilizing slot. The stabilizing slot is positioned tobe at lest partially vertically collinear with stabilizing slots inother vertically adjacent blocks when positioned with respect to eachother in an interlocking configuration to form a wall face. Alsoincluded are a plurality of reinforcing tendons, each placed in aselected stabilizing slot through a plurality of the main blocks. Eachof the reinforcing tendons is sized with respect to the stabilizing slotto permit movement of the main block along at least one horizontal planefor a predetermined extent in a direction perpendicular to at least oneface of the wall. Each of the reinforcing tendons is connected insidethe wall at one end and connected at the top of the wall at the otherend.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1(a) is a perspective diagram depicting the main block component ofthe inventive wall system.

FIG. 1(b) is a perspective diagram depicting the rear view of the blockof FIG. 1(a).

FIG. 2 is a perspective diagram depicting a sill cap.

FIG. 3 is a perspective diagram depicting a corner block.

FIG. 4 is a perspective diagram depicting a short block.

FIG. 5 is a perspective diagram depicting a partially assembled wallusing the inventive system.

FIG. 6 is a top view of the first course of a wall constructed accordingto the present invention.

FIG. 7 is a cross sectional view of a portion of a wall assembledaccording to the present invention, under 1 set of external conditions.

FIG. 8 is a cross sectional view of the structure of FIG. 7 underdifferent external conditions.

FIG. 9 is an elevation view of the wall according to the presentinvention, depicting placement of reinforcement rods.

FIG. 10 is an elevation view depicting the distribution of force on awall according to the present invention.

FIG. 11(a) is a perspective view of a main block used in anotherembodiment of the present invention.

FIG. 11(b) is a bottom view of the block of FIG. 11(a).

FIG. 11(c) is a top view of the block of FIG. 11(a).

FIG. 11(d) is an end view of another variation of the present invention.

FIG. 11(e) is an end view of still another variation of the presentinvention.

FIG. 12(a) is a perspective view of a corner block used in furtherembodiment of the present invention.

FIG. 12(b) is a front view of the corner block of FIG. 12(a).

FIG. 12(c) is a first end view of the corner block of FIG. 12(a).

FIG. 12(d) is a top view of the corner block of FIG. 12(a).

FIG. 12(e) is a bottom view of the corner block of FIG. 12(a).

FIG. 13(a) is a perspective view of a corner block of another embodimentof the present invention.

FIG. 13(b) is a first end view of the corner block of FIG. 13(a).

FIG. 13(c) is a first side view of the corner block of FIG. 13(a).

FIG. 13(d) is a top perspective view of the corner block of FIG. 13(a).

FIG. 13(e) is a bottom perspective view of the corner block of FIG.13(a).

FIG. 14(a) is an end view of the positional variation of a masonry blockhaving further aspects of the present invention.

FIG. 14(b) is a detailed view of FIG. 14(a).

FIG. 14(c) is an additional detailed view of FIG. 14(a).

FIG. 15 is an end, cut-away view of a wall system incorporating aplurality of blocks similar to those depicted in FIG. 14(a).

FIG. 16 is a side view of an additional element constituting the wallsystem of FIG. 15.

FIG. 17(a) is a top view of an additional block embodiment havinginventive features, and used in the context of the original invention.

FIG. 17(b) is a side view of the block of FIG. 17(a).

FIG. 17(c) is a side view of the block of FIG. 17(a), depictingadditional inventive features.

FIG. 18(a) is a top view of a corner block used in conjunction with theblock of FIGS. 17(a)-17(c).

FIG. 18(b) is a front view of the block of FIG. 18(a).

FIG. 18(c) is a side view of the block of FIG. 18(a).

FIG. 19(a) is a bottom perspective view of the bottom of the block ofFIG. 17(a).

FIG. 19(b) is a top perspective view of the block of FIG. 17(a).

FIG. 19(c) is a perspective view, taken at a different angle from thatof FIG. 19(b).

FIG. 19(d) is a perspective view taken at a different angle of the blockof FIG. 19(a).

FIG. 20(a) is top perspective view of the corner block of FIG. 18(a).

FIG. 20(b) is a bottom perspective view of the corner block of FIG.18(a).

FIG. 20(c) is a bottom perspective view taken at a different angle ofthe block of FIG. 20(a).

FIG. 20(d) is a top perspective view taken from a different angle of theblock of FIG. 20(b).

FIG. 21(a) is a perspective view depicting an inventive configuration ofalternating corner blocks.

FIG. 21(b) is a perspective view from a different angle of FIG. 21(a).

FIG. 21(c) is an additional perspective view of the block arrangement ofFIG. 21(b).

FIG. 21(d) is an additional perspective view of the block configurationof FIG. 21(a), taken from another angle.

FIG. 22(a) is a top view of the block configuration of FIG. 21(a).

FIG. 22(b) is a top view of two horizontally adjacent blocks such asthose depicted in FIG. 19(a).

FIG. 22(c) is a top view incorporating the block arrangement of FIGS.22(a) and 22(b).

FIG. 23(a) is a perspective view of the block arrangement of FIG. 22(c).

FIG. 23(b) is a perspective view of the block arrangement of FIG. 23(a),taken from a different angle.

FIG. 23(c) is a side view of a stack of blocks, such as those depictedin FIG. 17(a).

FIG. 24(a) is a side view depicting the horizontally tensioned structureof masonry blocks, such as a lintel structure.

FIG. 24(b) is a top view of the arrangement of FIG. 25(a).

FIG. 24(c) is a side view of FIG. 24(a).

FIGS. 25(a)-25(c) depict the end piece hardware and its mounting for thearrangement of FIGS. 24(a)-24(c).

FIG. 26 is a front view of a wall arrangement containing the structureof FIGS. 24(a)-24(c).

FIG. 27 is a sectional side view depicting a wall system verticallysectionalized to separate the vertical sections, such different stories,from each other, and to provide additional reenforcement.

FIG. 28(a) is a side sectional view depicting the relationship betweenan aligning tool, a bearing plate, and a block to be mounted on thebearing plate.

FIG. 28(b) is a detailed view of the tool depicted in FIG. 28(a).

FIG. 29(a) is a sectional side view of a block mounted on a footing.

FIG. 29(b) is a detailed view of a reenforcing rod found in FIG. 29(a).

FIG. 30(a) is a side sectional view depicting the arrangement of a toolfor aligning a reenforcing rod within a block/footer arrangement.

FIG. 30(b) is a detailed view of the tool depicted in FIG. 30(a).

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1(a) and 1(b) depict two perspective views of the main blockconstituting the present invention. The drawing designation numeralsincluded in FIGS. 1(a) and 1(b) remain the same for all of FIGS.1(a)-10. For the sake of clarity and efficient consideration of all ofthe drawings, the legend of the drawing designation numerals is providedbelow: 11. square receiving slot 12. dovetail 13. through holes 14.stabilizing holes 15. upper plane 16. lower plane 17. upper shoulder 18.lower shoulder 19. interior sides 20. exterior sides 21. front plane 22.rear plane 23. front shoulder 24. rear shoulder 25. dovetail receivingslot 26. corner block 27. cynderbrick (main block) 28. short block 29.footer 30. foundation

The wall system of the present invention is essentially composed ofthree basic components. These include: a main block, a corner block, andshort block. The main block, shown in FIGS. 1(a) (front view) and 1(b)(rear view), is the fundamental component upon which the entire wallsystem is based. It is rectangular in its general shape and possess anumber of crucial features that set it apart from the conventional art.Situated on the upper plane 15 is a male dovetail 12 extending up fromthe front plane 21 and back to approximately one-half the length of thecynderbrick. Running along the lower plane 16, parallel to the maledovetail 12 on the upper plane 15, is the combination square receivingslot 11 and dovetail receiving slot 25. The square receiving slot 11runs approximately one-half the length from the front plane 21 and thengradually turns into the dovetail receiving slot 25.

This feature enables a new main block to be placed directly over the topof a main block on the lower course. Here, the square receiving slot 11of the main block freely receives the dovetaile 12 of the main block onthe lower course. The new main block is then slid one-half its length sothat, as the square receiving slot 11 turns into dovetail receiving slot25 on the new main block, it engages the male dovetail 12 on the mainblock on the lower course and is locked into position staggering thevertical joints. This feature overcomes the assembly difficulties foundin prior art where each new block must be slid over a number of otherblocks on the lower course into the appropriate position. It is alsoeasier to fit the blocks of the present invention onto other such blocksthan with similar conventional art interlocking wall systems. This isdue to the fact that the tolerances between the dovetails and thedovetail slots of the present invention are quite large so that there iseasy assembly. The use of large tolerances between the interlockingpieces has benefits that are explained infra. On the other hand, inconventional interlocking wall systems, the tolerances between the slotsand pieces that are meant to extend into the slots are quite small. Theresulting tight fits are necessary for the proper assembly of suchconventional art walls but make the assembly quite difficult. Thisdrawback is not shared by the system of the present invention.

The sides of the main block 19, 20 are off-set (in a parallel manner)both horizontally and vertically creating interlocking shoulders 17, 18,23, 24 when mated to adjacent blocks. This provides the blocks withhorizontal and vertical stability. The lower shoulder 18 also acts as adrip edge resisting water penetration. Running at a vertical axisthrough the center of the main block are two stabilizing holes 14. Thesehole loosely accommodate either steel reinforcement rods or squaretubing as shown in FIGS. 7, 8 and 9. Optional through holes 13 may beadded to reduce the amount of cement and/or other material used tomanufacture the component.

Both the corner block shown in FIG. 3 and the short block shown in FIG.4 employ the same features as the main block with the exception of theinterlocking dovetail. The interconnection of these components isillustrated in FIGS. 5 and 6. A sill cap, as depicted in FIG. 2 isemployed over the top of the last course to help lock the course ofblocks into place, and to provide a surface for subsequent framing ifrequired.

While the aforementioned blocks may appear similar to those found in theconventional art examples, the differences that have been pointed outare very significant with respect to the manner in which the walloperates to distribute external stress. While all interlocking blockspossess some play by virtue of the tolerances necessary to interconnectthem, none possess the attribute of variable dynamic resistance. Theterm, dynamic resistance, can be defined as the property of a structureto slightly give under pressure and then lock up as a solid mass at agiven point. Thus, variable dynamic resistance is dynamic resistancethat can be adjusted to suit construction and environmentalrequirements.

The operation of this property is effected by a combination of block fittolerances and the use of either steel reinforcement rods or squaretubing loosely placed through the stabilizing holes 14 at the top. Bychanging the number of rods and their placement, a considerable degreeof variation can be achieved. Simply put, more rods in more places meansless fluidity and more rigidity. Conversely, fewer rods in fewer placesmeans more fluidity and less rigidity. This property substantiallyincreases wall integrity and reduces the common cracking found incontemporary wall construction. Also, the tolerance between thestabilizing hold and the forcing rods can also be adjusted to adjust thedegree of wall movement permitted.

When forces such as hydrostatic pressure are exerted against the wallsurfaces, each cynderbrick moves slightly. The first movement occursproximate to the pressure. As this block moves to its predeterminedtolerance (when the dovetail jambs against the side of the slot and thereinforcing rod jambs against the side of the whole containing it), itautomatically locks in place and then transfers this force to the sixadjacent blocks (two top, two bottom and two sides, see FIG. 10). Theseblocks likewise move a predetermined extent until they reach the end oftheir tolerance and then they, in turn, transfer the force to the otheradjoining blocks. This allows the entire wall to progressively andsystematically absorb the force moving gradually as it does. This radialtransfer is illustrated in FIG. 10 where the darker areas represent thegreater degree of stress and earlier lock-up in the progression.

Strategically placed within the wall are either steel reinforcement rodsor square tubing as seen in FIG. 9. These run in a vertical fashion andare used to stabilize the wall when it reaches the end of its toleranceand locks up. Unlike all of the conventional art, the steelreinforcement rods or square tubing are loosely placed with the verticalholes as depicted in FIG. 8. This space between the hole and thereinforcing rod (along with the tolerance between the block dovetailsand their associated slots) permit movement of the wall up to a point.This is when the side of the dovetail jambs tight against the side ofit's respective slot and the reinforcing rod jambs tightly against thehole through which it is placed. Thus, these elements act in conjunctionto provide controlled movement and positive lock-up.

When the wall is in locked-up state, all of the blocks have reached theend of their predetermined tolerances and the force is now transferredto either the steel reinforcement rods or the square tubing as shown inFIG. 7. This transfer is possible because the space between the steelreinforcement rods and the vertical holes in the cynderbricks arereduced as a result of the block movement up to this point. Thereinforcing rods now act to stabilizing the structure. This, in turn,further limits the movement of the wall and positively acts to resistthe applied pressure. Because of the interlocking dovetails and themanner in which the horizontal and vertical surfaces connect, each blockcontributes to resist the force. Thus, the present structure operates todistribute the force on any particular block or blocks, as depicted inFIG. 10. As a result, instead of all the force being placed upon theblock (depicted as the darkest block in FIG. 10), the force isdistributed to surrounding blocks and in diminishing measure to thoseblocks surrounding them. By spreading the force as depicted in FIG. 10,it is far less likely that sufficient stress will be built up on oneblock or group of blocks to cause the wall to fail at a particularpoint. This makes the wall a strong interconnected mass able towithstand far more force than its traditional counterparts.

There are five factors that contribute to the property of variabledynamic resistance. These can be divided into two general categories:fixed and variable. The fixed factors are those designed within thesystem and cannot be altered unless the dimensions are modified. Theseinclude the overall size of the cynderbrick, the tolerance between eachcynderbrick and the size of the stabilizing holes. The variable factorsare those that can be adjusted by the assembler. Among these are: thenumber and placement of the either the steel reinforcement rods or thesquare tubing.

The unique physical characteristics of the masonry components, workingin conjunction with the loosely placed rods/tubing, produces the highlyefficient distribution of force over a large segment of the wall,enabling the wall not only to accommodate gradual directional forcessuch as settling and hydrostatic pressure, but rapid omnidirectionalforces such as seismic disturbances. The wall structure whichfacilitates the property of variable dynamic resistance, creates atechnique for dealing with omni-directional external pressures.

The flexible walls of the present invention can accommodate themovements found in earthquake zones. In contrast, the rigid conventionalwalls, such as those found in residential foundations, will directlytransfer the seismic force to the rest of the building cumulativelyweakening the integrity of the structure until it eventually fails. Notonly does the present invention overcome this significant problem, butit also has the added features of:

-   -   (a) providing an improved masonry wall system that does not        require skilled labor to assemble;    -   (b) providing an improved masonry wall system that is mortarless        in construction;    -   (c) providing an improved masonry wall system with rapid on-site        assembly;    -   (d) providing an improved masonry wall system that can be        disassembled and reused;    -   (e) providing an improved masonry wall system that overcomes the        problems commonly associated with dovetail assemble.

It will be understood by one skilled in this art that any number ofdifferent configurations of front shoulders, rear shoulders, uppershoulders and lower shoulders (17,18,23,24), as well as other relatedinterlocking structures can be used within the scope of the presentinvention. Further, any combination of square receiving slots 11 (inFIG. 11(e)) and dovetail receiving slots 25 can be used. One example isfound in FIG. 11(d) which depicts the combination of a square slot foreasy fitting of two adjacent blocks and a dovetail receiving slot 25 tomore closely hold the two adjacent blocks together.

The embodiment of FIGS. 11(a)-11(d) differs from that previouslydescribed by virtue of a second receiving aperture 41, which is designedto hold an upper connecting stud 42 such as that depicted in FIG. 12(a).The embodiment of FIG. 11(a) can include dovetaile 12 as an upperinterlocking device, or can use a rectangular structure as in FIG. 11(e)in lieu of the dovetail.

FIGS. 12(a)-12(e), as well as FIGS. 13(a)-13(e) depict two additionalembodiments of the present invention. All of the blocks depicted inthese drawings are corner blocks. The blocks of FIGS. 12(a)-12(e) andthose of FIGS. 13(a)-13(e) are meant to alternate with each other so asto create a staggered vertical seam at the interface of the cornerblocks and the main blocks.

An alternative to dovetaile 12 or a rectangular key structure,interconnecting studs 42 (as depicted in FIG. 12(a)) can be substituted.Either one such stud or two, as depicted in the drawings can be usedwhere appropriate. The use of the connecting studs rather than theelongated dovetail structure or elongated dove structure can often makeassembly of the blocks easier. This can be especially important whentrying to alternate between different types of corner blocks (such asthose depicted in FIGS. 12(a)-12(e) and 13(a)-13(e)) in order to avoid avertical seam line on either side of the corner blocks. The avoidance ofthis seam line is especially important in further strengthening the wallsystem.

It should be evident to one skilled in this art that virtually anyconfiguration of wall block can be used within the concept of thepresent invention in order to provide the desired configuration of thevarious blocks depicted in the drawings, as well as those having otherinterlocking configurations that would occur to one skilled in this art.

The blocks can be made of any masonry material including cellularconcrete or other light weight materials such as the auto-clave, aeratedconcrete used in many structural materials. This will allow the systemof the present invention to be used in a wide variety of differentstructural applications.

Further, the blocks used in the present invention can be molded orotherwise formed to include conduit runs, ventilation connections or anyother configuration to accommodate other building materials to be usedwith the wall system. Consequently, the wall system of the presentinvention can be configured to accommodate all of the structures thatmight be used as part of a building which includes the presentinvention. Such formations can also include aesthetic features, such ascolors, different textures for the surface of the wall, and evenbase-relief designs.

Because the concept of the present invention can be carried out using anumber of different materials for the blocks, the wall system of thepresent invention can be down-scaled to be used for modeling purposes,or even as toys. Accordingly, the materials used to manufacture theblocks are to be of sufficient density to accommodate the various shapesof the blocks on a scale appropriate for toys or models. While evencellular concrete may not be appropriate for this application, othermaterials can be used. For example, plastic, rubber or even wood can beused to duplicate the inventive wall system for purposes of creatingworking models or toys.

When the present invention is used in a model or toy application, thereinforcing rods depicted in FIGS. 7 and 8 can be made of a number ofdifferent materials since structural steel would not be required forsuch applications. For example, the rods can be made of elongatedplastic or rubber. In order to simulate the actual variable dynamicresistance of the present invention, the rods are preferably made of aflexible metal material, even for modeling or toy applications.

The reenforcing rods can be further made more effective and hold thewall system together more throughly from top to bottom if the rods arethreaded at both ends is described infra with respect to FIGS. 15 and16. This would allow the lower part of the rod to be threaded into athreaded receiving piece formed into the concrete foundation, such asbearing plate 92 in FIG. 15. The upper end of the reenforcing rod wouldalso be threaded to allow a nut to hold a plate, such as cap 95, to thetop of the wall. Such an arrangement would make the wall system moreable to withstand the stresses caused by earthquakes and other massivedisruptions. The tightness of the bolted plates at the top of the wallshould be adjusted depending upon the amount of movement that would beconsidered desirable for the wall system.

Further stability could be obtained by forming a templet (preferably ofmasonry material) as part of the foundation on which the wall of thepresent invention would be placed. Such a templet could have theconfiguration of upper interlocking structures depicted in the drawings.Such interlocking structures on the templet would interlock with thelower interlocking structures of the first row of blocks of the wall,thereby forming a more stable structure. In the alternative, such atemplet could be formed separately, and include only as much material asis necessary for the basic interlocking between adjacent blocks. Such atemplet could be bolted directly to the foundation in a manner wellknown to those skilled in the art so that the first course of fullblocks would be interlocked onto the templet. To facilitate ease ofinstallation and flexibility in assembling the wall system, the templetcould be made of a number of materials other than the masonry used toform the main part of the wall system. For example, the templet could bemade of metal (preferably rust-resistant), hard rubber, nylon, plastic,or even pressure-treated wood.

The previously-described embodiment provides an entirely new concept interms of masonry wall resiliency. However, certain problems of masonrywalls require further modification. In particular one particular problemis the occurrence of point loading due to nonuniformity in masonry blockconstruction. Traditionally, dry, stacked blocks have been unsuccessfulin maintaining consistency because standard block molding machines lackthe capability of uniform construction. Because certain parts of theblock, such as the flanges, protrude, phenomenon called point loadingoccurs. One example is when a protrusion on a flange due to nonuniformconstruction becomes the sole point upon which the flange of the blockrests upon the block below it. This significantly reduces the structuralintegrity of the wall, as well as rendering accurate leveling and sizingof the wall very difficult. This is especially problematical with wallsof the present invention since the mortar which is used to achieve leveluniform walls is not used to connect vertically adjacent blocks in thewall system of the present invention. Accordingly, only the top capwhich is connected to the top row of blocks using mortar or grout canconventionally be used to level the wall in attempt to achieve a uniformheight.

To address this problem, an additional embodiment of the presentinvention uses blocks (depicted in FIGS. 14(a)-14(c)) that have groundbearing surfaces to obtain uniformity, and avoid point loading. A closefit for vertical interlocking between adjacent blocks 50 is provided bygrinding the upper surface of flanges 51. Also, surface 54 on interiorweb 53 is molded to interface closely with surface 52 of flange 51. Bothsurfaces 54 and 52 are molded to achieve an angle of 15

from vertical. A typical arrangement that has been used includes anextension of interior web 53 approximately 0.375 inches above flanges 51at the top of block 50. The flanges extend approximately 0.625 inchesbeyond the interior web 53 at the bottom of the block. These dimensionsare typical for a block approximately 0.375 inches tall, andapproximately 7.726 inches wide. These are dimensions substantiallyconsistent with standard CMU-sized blocks.

The normal molding process for masonry blocks can insure that propertolerances are maintained on all surfaces and edges, except for the topedge of flange 51. In the normal molding process the upper surface offlange 51 is subjected to variances of up to 1/16 of an inch, and canresult in the aforementioned irregularities. The other portions of theblock are contained within the mold, and so are not subjected to thisproblematical situation. Accordingly, it is only the upper edge offlange 51 that must be ground in order to achieve a close fit with avertically adjacent block. It should be noted that the bottom surface offlange 51 is subjected to tight mold tolerances, and so does not sufferfrom the aforementioned variance.

The grinding is preferably done at the factory once the block is molded,or can be carried out in the field immediately before installation ofthe blocks. As a result of this grinding operation, vertically adjacentblocks fit together in and are vertically supported along the entire topand bottom of the flange 51, as well as the molded 15

beveled surface 54 interfacing with 15

beveled surface 52.

It should be noted that while the aforementioned dimensions are suitablefor blocks of the CMU standard size, this embodiment of the presentinvention is not limited thereto. The benefits of this embodiment of thepresent invention can be obtained with smaller or larger blocks, andwith beveled surfaces, either greater or less than 15

. The key requirement is that the beveled surfaces be uniform along withthe upper surfaces and lower surfaces of flanges 51. The interfaces ofthe beveled surfaces provide a high degree of flexible interlockingbetween vertically adjacent blocks.

The interlocking of the previously-described embodiment has certainconstraints. If the interface between the beveled surfaces is madeextremely tight, and within narrow tolerances, the capability of thewall to properly flex under external stresses may be somewhatcompromised. Accordingly, tolerances for the aforementioned embodimentshould be only as close as necessary to achieve a lose interlock. Atight interlock is not effective if the wall is to flex to anysubstantial degree. Control of such flexing must be based upon the useof the support structures described with respect to the previouspreferred embodiment (FIGS. 1-13) of the present invention.

The reenforcing capability of these rod-like structures can be extendedusing the arrangement of FIGS. 15 and 16 in a further embodiment of thepresent invention. The reenforcing structures are preferably verysimilar to standard metal (iron or steel), which is a standardreenforcing device in conventional wall systems. However, unlikeconventional rebar, or the support structures of the previous preferredembodiments of the present invention, the support tendons 70 arethreaded at at least one end, and attached to the wall system at bothends. By tightening the nut 81 (FIG. 16) against a lintel or cap 95,while connecting support tendons 70 at its other end to a bearing plate52 at the bottom of the wall, vertical pressure is exerted throughoutthe vertical courses of blocks 501-50N of wall 100.

By increasing or decreasing the tension on the top cap or lintel 95through nut 81, the tightness of supporting tendon 70 within aperturesin the block 50 can be adjusted. This tension is most easily adjustedthrough the use of compensating spring 80, which is held between springcaps 83. The spring caps rest upon sill 95 so that force created bytightening nut 81 is transmitted through the cap 95 and into the block50N-501 as vertical force. This vertical force can control how muchflexing is permitted by the block of the wall. The tension created bytightening or loosening nut 81 on threaded portion 72 of tendon 70 willdetermine to a large extent how far the blocks can move in a horizontaldirection before locking up with the tendons 70, as described withrespect to the previous embodiments (FIGS. 1-13) of the presentinvention. The use of spring 80 also increases the amount of externalforce the wall 100 can absorb without damage.

However, with the previous embodiments (FIGS. 1-13) of the presentinvention, only a certain amount of flexing is permitted, and this isdetermined by the size of the tendon and the size of the holes in theblock through which the tendon passes. Once the blocks have beenmanufactured and assembled into the wall, no adjustments of the degreeof flexing permitted can be carried out without massive structuralchanges in the wall.

This instant embodiment (FIGS. 15 and 16) of the present inventionpermits for adjustments in the degree of wall flexibility after the wallhas been erected, without reassembling the wall or changing the sizes ofthe apertures through which the tendon passes, or the tendonsthemselves. Through the use of the embodiment depicted in FIGS. 15 and16, the amount of wall flexing can be adjusted, and the force underwhich the wall flexes can also be more precisely determined. The factthat forces on the wall are ultimately absorbed by the spring 80, meansthat the wall becomes more resilient, and is more likely to move back toits original position when the external forces are removed. This isespecially helpful when walls having the present invention are subjectedto seismic forces.

In order to achieve the tensioning of the wall in the vertical directionthrough the use of tendon 70, it is necessary that the tendons beconnected at its second end to a structure at the base of the wall. Itis necessary that the structure be arranged so that the vertical forcesgenerated by tension on the tendon be transmitted upward vertically. Inthe preferred embodiment of FIGS. 15 and 16, this is provided by abearing plate or base plate 92 at the bottom of the lowest block 501 inthe vertical stack through which tendon 70 passes. Preferably, tendon 70has a threaded portion 72 at both ends. At the lower end, threadedportion 72 is screwed into threaded receptacle 93 of the bearing plate92.

While this is the preferred method of carrying out this particularaspect of the invention, it is not absolutely necessary. Instead tendons70 can be set into a mortar bed 91 which does not contain bearing plate92. The mortar bed is supported by footing 90. Pressure is applied tothe opposite end of tendon 70 through tightening nut 81 against washer82 and spring caps 83 to create the vertical force through cap 95.However, this alternative arrangement is not nearly as stable or easy toimplement as that depicted in FIG. 15. While a mortar connection for thelower end of tendon 70 has been shown to be adequate for the previousembodiments (FIGS. 1-13) of the present invention (where movement of theblocks is eventually stopped entirely by a locking action with tendons70), this connection arrangement is not nearly as effective whenapplying tension through tendon 70 by the tightening of nut 80 to createvertical forces throughout the wall 100. Accordingly, a metal(preferably steel or iron) bearing plate 92 is preferred.

Since extremely long pieces of rebar are conventionally used, they areextremely awkward to handle. Because tendons 70 have threaded portions2, shorter portions of the tendons can be used for the sake of easierhandling. For tall wall sections the tendons are connected to each otherusing couplers 71. This is easily accomplished due to the threadedportion 72 of the tendons.

The assembly of tall walls leads to additional problems. Even ifassembly of the tendons has been simplified through the use of threadedcouplers 71, there are still problems with fitting blocks 50 on top ofeach other by passing a fixed tendon 70 through a hole in the block.Further, blocks such as those shown in FIGS. 1-14 can be awkward tohandle when placing one block on top of another due to a lack of easyhand holds on the block. This is especially critical when fitting blocksover tendons to create tall walls of block.

This problem is addressed in part by the block configuration depicted inFIG. 15, and further defined in FIGS. 17(a)-17(c). One advantage of thisdesign of block is a space 55 left beneath webbing 53. This arrangementallows an installer or other mason to easily grab the block 50 at thebottom well above the bottom of flanges 51, which contact the top of theexisting course of the blocks. The same type of block manipulation isnot done nearly as easily using the block configuration of FIGS.14(a)-14(c). As depicted in FIG. 17(c), this space 55 is approximatelytwo inches in height, easy enough to be handled conveniently by aninstaller placing the block on an existing row of blocks. It should alsobe noted that this two inch space 55, which is only representative ofthe size of its space that can be used, can also be used as a ready-madeconduit area. Thus, space 55 eliminates the necessity of the drillingholes through interior web 53 of block 50. As a result, installation ofthe blocks in a complex wall system becomes much easier. Further,masonry walls made from this kind of block are easier to incorporate incomplex buildings.

While the aforementioned block configuration aids in the installationand handling of the block, it does not of itself eliminate the awkwardnecessity of threading block over a standing tendon using a smallaperture in the block, as is required in the previous embodiments (FIGS.1-13) of the first invention. This difficulty is addressed by the mainor stretcher blocks of FIGS. 17(a)-17(c) and the corner block of FIGS.18(a)-18(c). Instead of an aperture as depicted in FIGS. 1-13 of thepresent application, a slot 56 is provided. Slot 56, as with theaperture of FIGS. 1-13, is sized in relationship to the size of thetendon to be held therein, and the amount of maximum movement that is tobe allowed before the blocks lock up with the tendon. As one example,for a standard CMU block, the slot can be 1¾ inch by 1 ¼ inch.

The size of the slot 56 will also be adjusted based upon the tightnessof the nut 81 on the tendon 70 applying vertical force to the wall, andthereby further limiting the horizontal movement of the blocks 50 in thewall. As with standard blocks there are spaces 57 between the internalwebbing 53. The webbing is tapered internally from top to bottom. Thisfacilitates the insertion of foam cores into the spaces. The taper helpshold the foam cores more firmly and avoids the tendency for the cores todrop entirely through the spaces 57. The spaces 57 are generally 5inches by 3¾ inches. However, different dimensions can be used evenwithin the norm of a standard CMU-sized block.

Horizontal interlocking between horizontally adjacent blocks 50 isfacilitated through the use of web extension 58, which is located at theend of the block 50 opposite slot 56. Structure 58 is an extension ofinterior web 53, extending approximately ¾ of an inch beyond flanges 51.A 15

bevel is applied to both sides of web extension 58 in order to moreeasily interface with the extending flanges 13 of the horizontallyadjacent block 50. The bevel permits a certain amount of movement ofhorizontally adjacent blocks with respect to each other, as isconsistent with the concept of the basic invention which relies upon thetendons 70 as the ultimate locking device when blocks are subjected toforces that cause horizontal movement. Yet, even within theseconstraints, the horizontal interlocking provided by fitting ofextension 58 into flanges 51 of a horizontally adjacent block is anextremely desirable feature since the horizontal interlocking mechanismis relatively easy to manufacture and use in assembly of wallsconstituted by main blocks 50.

The perspective views of FIGS. 19(a)-19(d) provide a better idea of howthe main block 50 would fit together horizontally along the same courseof blocks. For ease of handling, the block is usually grasped from thebottom at one of the web pieces 53. When the wall is assembled, thetendons are placed upright through the blocks of the wall. Accordingly,when a block is placed on an existing row of blocks, the block ismanipulated so that the open end of the slot 56 is moved to the tendon.The use of the open end of the slot 56 removes the necessity of fittingthe entire block over the tendon 70 rather than simply sliding the blockagainst the tendon. An example two blocks fit together horizontally isdepicted in FIG. 22(b). A multiple course of blocks is depicted by thetop view of FIG. 22(c). A sectional end view of a stack of blocks 50 isdepicted in FIG. 23(c).

An additional structure is depicted in FIG. 17(c). There are threegroves or troughs 59 formed in the upper surface of both flanges 51 andinterior web sections 53. The troughs are best depicted as shown in FIG.17(c), and are arranged in the middle of the web structure 53 and at thesurface 54 where the web structure interfaces with the flanges. Thesetroughs allow water that has entered the interior of the wall to draindownwards through the wall spaces 57 as quickly as possible. Once thewater has reached the bottom of the wall, conventional drainagetechniques can be used to carry it away from the wall. Because theconventional techniques are already well-known to those skilled in thisart, further elaboration upon them is not necessary. The key attributeof this embodiment of the present invention is the use and placement oftroughs at the top of each of the blocks. The troughs 59 can be formedin the blocks during manufacturing by conventional molding processes, orthe troughs can be cut or ground into the blocks before installation.

Drainage troughs are also found on corner blocks, such as those depictedin FIGS. 18(a)-18(c). Each corner block has two slots 66 on oppositeends of the block 60. Like the main block 50, the corner blocks haveinterior webbing 63 with spaces therebetween. Troughs 69 are formed inthe interior webbing in the same manner as is done is done for the mainblocks 50. The general size of the corner blocks is comparable to thatof the main blocks. Like the main blocks, the webbing 63 of the cornerblocks is tapered downward to help hold core insulating material in thespaces between the webbing. The corner block 60 also has a conduit space65 of approximately two inches in height in order to permit easyhandling of the block, and the provision of conduits in the same manneras is done for the main blocks 50.

Unlike main blocks 50, the webbing 63 of corner block 60 remains belowthe flanges 61 by approximately ⅜ of an inch for a typical block of CMUstandard size. Like the main blocks 50, the vertical edges of theflanges of the corner blocks are beveled or chamfered for ease ofhandling. FIGS. 20(a)-20(d) depict various respective views of oneorientation of corner block 60. It should be noted that there are alwaystwo slots 66 for each corner block and that these have opened endsfacing 90

with respect to each other.

FIGS. 21(a)-21(d) depict perspective views of two rows of corner blocks60 stacked on each other. As is clear from the subject drawings, thelower block has its own longer portion arranged 90

to the longer portion of the upper corner block. However, both blockscan be exactly the same. The change in orientation is effected simply byturning over one of the blocks. It should be noted that if this is doneslight modifications from the corner block of FIGS. 18(a)-18(c) can bemade to facilitate this arrangement. In particular, the flanges 61 canbe arranged to extend approximately an inch to two inches aboveinterwebbing 63 at both the top and the bottom of the block. It shouldbe noted that troughs 69 are arranged on both the upper and lowersurfaces of interior webbing 63 so that when corner blocks 60 is turnedover to change its orientation for alternating courses of block, thebeneficial effects of the troughs are still retained. Even if no othermodifications are made to the corner block 60, it can be used in thismanner.

In the alternative, a second type of corner block with an oppositeorientation can be manufactured and used for alternating the orientationfrom one course of blocks to the next. While this arrangement may resultin easier handling of blocks unmodified from those of FIGS. 18(a)-18(c),this is not the preferred arrangement. The use of a corner block havingan alternating orientation requires that a third block be manufacturedfor the inventive wall system, rather than only the two depicted inFIGS. 17(a)-17(c) and 18(a)-18(c). Any necessity to make additionaltypes of blocks raises the overall cost of the wall system, and so, isto be avoided. Thus, one of the major advantages of this aspect of thepresent invention is that an entire wall system can be constructed usingonly two types of blocks.

One advantage of the alternating orientations of the corner blocks isthat the slots through which tendons 70 pass are changed in orientation.Thus, one slot will have its open end 90

from the open end of the slot of the next course of blocks. This helpscreate a substitute for the enclosed aperture used to hold the tendon inthe previous embodiments of FIGS. 1-13 of the present application.Further, tendons need not be put under pressure for the corner blocks.Rather, they may simply be placed loosely in the stacked slots, servingas rebar in the traditional sense of this structure. In a minoralternative, the tendon, serving as conventional rebar can simply beheld at the base of the wall by grout or other conventional methods. Theuse of tendons 70 under tension as provided by the tightening of aspring-loaded nut on a lintel is applied to selected points along themain block 50 constituting the majority of the wall. This arrangement isalso depicted in FIG. 22(a) and FIG. 22(c).

The tensioned tendons 70 are arranged through slots 56 of main blocks 50in order to provide the benefits of adjustable wall flexibility. Theeffects of a solid, entirely enclosed aperture is achieve by alternatingthe orientation of main blocks 50 from course to course. The result ofthis arrangement is depicted in FIGS. 23(a) and 23(b). The alternatingslot orientations of alternating rows of blocks create the effect of anenclosed aperture which tendons 70 are arranged.

The result is also an alternating seamline so that the only completeseams running from the top to the bottom of the wall are found at thecorners. This is crucial to the integrity of the wall since a straightseamline between blocks along the vertical height of the wall leads to anumber of drawbacks for such a wall system. As depicted in FIGS. 23(a)and 23(b), the tendon going through each of the corner blocks for aparticular corner can be placed loosely, and can be constituted by anepoxy bar, operating in a conventional rebar role.

The main blocks 50 appear to each contain one tendon 70, which will beput under tension to achieve the benefits of the present invention.However, the placement of the tendons 70, as shown in FIGS. 23(a) and23(b), is not necessary for the operation of the present invention.Rather, any arrangement for spacing of the tendons can be used,consistent with the concept of the present invention. Such spacing isusually determined by the kind of forces (such as seismic effects) thatwill be placed upon a particular wall system. The placement and spacingof the tendons will also, to some extent, determine the level of tensionto be placed upon each of the tendons. These factors can also be alteredbased upon the height of the wall, as well the types of loads to beplaced on the wall system.

Vertical tensioning of support tendons is only one aspect of the presentinvention. The tensioning of horizontal supports or tendons can also becarried out as another embodiment of the present invention. FIGS.24(a)-24(c) depict a horizontal support arrangement using tendons 85under tension using side plates 96. This technique can be used to createstable horizontal structures of masonry block to serve as lintels, forexample. An arrangement of such a lintel 200 is depicted in FIG. 26. Thelintel supports the wall blocks 50 above an opening in wall section 100.Such a structure is created by placing tendons 85 as depicted in FIG.24(c). Preferably, the tendons are arranged atop the central webbing 53of block 50 in a manner that avoids blocking any of the water troughs59.

Structure 200 is provided with end hardware as depicted in FIGS.25(a)-25(c). The hardware is relatively simple, consisting of end plates96, which are curved in order to better interface with the ends of block50. This is especially important for the plate 96 which will fit betweenflanges 51. In the depicted embodiment, each of the end plates 96 isformed with four holes 98 for tendons 85. Preferably, the tendons areformed to have threaded portions at each end in order to accommodatebolts for tightening the tendons to provide horizontal tension which isapplied as horizontal pressure to the lintel structure 200.

The post tensioning aspects of the present invention can be arranged onwall systems constituting multi-story buildings. The overall tendons canbe made as long as necessary through the use of couplings 71, which areapplied to the threaded ends of the tendon 71. The tendon 71 can bescrewed into a pressure plate, or in the alternative, fixed in a footer90 or a mortar bed 91 on the footer. As depicted in FIG. 27 the wall isvertically sectionalized using a cap/lintel made of metal. Reenforcingbar or rebar runs horizontal along the course of the wall, and is fixedto the lintel 105 with stays 87. The cap or lintel is filled with groutor mortar to fix the rebar in position. Additional courses of block areplaced on the mortar-filled cap through control joints 107. At eachstory of the building, a cap/lintel 105 is placed atop the courses ofblock in order to provide better horizontal reenforcement. At the top ofthe last story of blocks, a sill 95 is used to support the tendon nut 80as previously described with respect to FIG. 15. The horizontal rebar 86can be constituted by threading tendons such as 70. These can be putunder tension in the same manner described with respect to FIGS.24(a)-24(c).

For all of the embodiments of FIGS. 24(a)-24(c), 25(a)-25(c) and 27,additional support for the horizontally tensioned structure is oftenneeded. This can be provided by filling selected spaces between interiorwebs 53 of the blocks with mortar or grout to form a solid structure.This is represented by filled space 97 in both FIGS. 24(a) and 24(b).The solid fill 97 for certain blocks 50 prevent the blocks fromcollapsing under high tension created by tendons 85.

The tensioning of tendons (both horizontal and vertical) creates a muchstronger, resilient masonry structure. However, the integrity of themasonry system can be undermined by misalignment, leading to unevenloading and the degradation of individual blocks. This can beexacerbated by the forces caused by tensioning tendons 70 and 85. Amajor problem can be misalignment of the lower course of blocks onmortar bed 91 and footer 90. When maximum pressures are developed usinga tendon 70, a bearing plate 92 is usually involved so that the footeris not degraded by the tension on the tendon. It has been discoveredthat alignment between bearing plate 92 and the bottom block 50 on thatbearing plate can be crucial when large forces are developed in thetightening of the nut 81 (FIG. 16) which forces sill 95 against the topcourse of the block.

In order to properly align the lower course of block 50 on bearing plate92, an alignment tool 110 (as depicted in FIGS. 28(a) and 28(b)) isused. The alignment tool 110 has a handle 111, and upper bearing plate112 and a captive ring 113. Extending from the upper bearing plate 112is a threaded tendon 114 ending in a threaded portion 115. This threadedportion is screwed into a threaded receptricle 93 on bearing plate 92.The lower course of blocks 50 is held as depicted in FIG. 28(a). Onceproper alignment of the block, bearing plate and footer are achieved,mortar is used to hold the bearing plate and the lower course of blockin place. Tool 110 is removed as soon as the grout or mortar is dried tohold the bearing plate and lower blocks 50. Once tool 110 is removed, astandard tendon 70 can be inserted. Since the bearing plate 92 has beenproperly aligned with the lower course of blocks, the tendon can beplaced and subsequent rows of blocks arranged around it without theproblems caused by misalignment.

It is crucial that the bottom course of blocks 50 be firmly attached tothe footer 90 and mortar bed 91 which is used to hold the block. Notevery block along the bottom course has its own bearing plate 92 andtendon 70. However, additional holding capability, beyond that providedby mortar, is often necessary. One technique has been the use of off-setmasonry spikes 120, such as that depicted in FIG. 29(b). The masonryspike is driven into the footer where it is held into place through theaid of its off-set construction. The top of the spike above the footerextends into the lowest block. Conventionally, mortar is used to fill inthe space around the off-set masonry spike within the bottom block 50.Typically, the masonry spike is driven through an aperture in the block.This is done with a hammer. Unfortunately, in conventional usage, thehammer is often brought too close to the block so as to knock it out ofalignment or damage the block. An additional problem exists in thatthere is no accurate way of determining the precise depth of the spikeas it is being driven in. Since the use of spikes can be crucial of wallsystems under a great deal of stress, the accurate use of masonry spikesin those blocks or tendons are not used can be very important.

This problem is addressed by driving tool 130 in FIG. 30(b). This toolhas an upper surface 131 for receiving blows from the hammer, and ahollowed-out portion 132 for receiving a masonry spike. The end of thehollowed-out portion interfaces with the top of the masonry spike 120and transfers the hammer blows against surface 131 to the masonry spiketo drive the spike into the footer 90. The bottom flange 133 comes torest on the footer once the spike has been driven into its proper depth.The tool 130 is then removed from the block, and the space around themasonry spike above the footer is filled in with grout or mortar.

Although the above description contains many specific details, theseshould not be construed as limiting the scope of the present inventionbut as merely providing illustrations of some of the presently preferredembodiments of the invention. Accordingly, the present invention shouldbe considered to include any and all variations, permutations,modifications and adaptations that would occur to any skilledpractitioner that has been taught to practice the present invention. Forexample, it is envisioned that other components using the same featuresmay be added later such as: partition blocks, end caps and lintels.Thus, the scope of the invention should be limited only by the appendedclaims and their legal equivalents, rather than the examples givenherein.

1. A flexible interlocking wall system including a plurality of blocksarranged for interlocking without mortar, said wall system having atleast two major surfaces, each major surface forming a wall space, saidwall system comprising: (a) a plurality of main blocks, each main blockhaving at least one stabilizing slot, said stabilizing slot positionedto be at least partially vertically collinear with stabilizing slots invertically adjacent main blocks when positioned with respect to eachother in an interlocking configuration to form a wall face; and, (b) aplurality of reinforcing tendons placed in selected stabilization slotsthrough a plurality of said main blocks, each reinforcing tendon beingsized with respect to said stabilization slot to permit movement of saidmain block along at least one horizontal plane for a predeterminedextent in a direction perpendicular to at least one said wall space,each said reenforcing tendon also being connected inside said wall atone end of said reenforcing tendon, and being connected at a top of saidwall at another end of said reenforcing tendon.